Environment

CSR initiative for truck drivers

Published

5 years ago

January 8, 2020

admin

Road transport has a sizable share in the logistics chain of cement business. The vital and important link of road transport is vehicle drivers. The author takes a close look considering the sustainability of the chain and how CSR can bring in meaningful change.

Today, the entire world is in the grips of an unprecedented crisis of a magnitude which no one had anticipated – the Covid-19 pandemic. This has shaken the fabric of the global society, which was already facing innumerable challenges. Amongst them, in the Indian context, is the issue concerning the well-being and training of our business partners in the road transport industry – the community of truck drivers who are a vital part of our supply chain to keep our economy rolling.

The fates of our business and the road transport industry are closely interdependent, with healthy growth of the cement industry directly correlated with the growth of the road transportation infrastructure. And the backbone of this infrastructure are the millions of truck drivers who on a daily basis move the manufactured produce from one end of the supply chain to the other. Corporates can benefit themselves only by benefiting society, which also includes the large truckers’ community.

Background – Importance of road transport in India
Road transport is considered to be the most cost effective and preferred transportation mode for freight, keeping in view its level of penetration into populated areas, easy availability, adaptability to individual needs and cost savings. No wonder that road transport has emerged as the dominant segment in India’s transportation sector and accounts for about 60 percent of freight traffic movement in the country. Road transport also acts as a secondary feeder service to goods transported by railways.

For cement, too, the major transport mode is road, accounting for almost 65 percent of total outbound cement despatches, and around 20 million tonnes of cement is transported by road every month through an estimated 2.5 lakh trucks. In addition, an equivalent number of trucks and bulkers are deployed to move the inbound raw materials like coal, flyash and gypsum to the manufacturing plants. Transit mixers for RMC further add to the total number of vehicles engaged in the cement industry.

At 5.9 million km, India has the second largest road network in the world (next to USA’s 6.9 million km) and the Ministry of Road Transport and Highways (MoRTH) is planning to add 60,000 km of roads over the next five years. Under the Make in India program of the Government of India launched in 2014, Roads and Highways was identified as one of the key focus sectors under the National Infrastructure Pipeline (NIP) for expansion, including the iconic Bharatmala Pariyojana. Rural road network is also being augmented under the Pradhan Mantri Gram Sadak Yojana (PMGSY). With the expansion of the road network in the country, it is anticipated that road transportation of goods will further increase in the foreseeable future.

Human manpower behind the wheels on the road
According to All India Motor Transport Congress (AIMTC) – the apex body of transporters – there are 9.3 million goods vehicles in India, including multi axle/articulated vehicles, smaller trucks, lorries, LMVs and tankers. As per industry estimates, India had a truck to driver ratio of about 1:1.3 in the early 90s which is estimated to have dropped to 1:0.75 today, and expected to drop further to an alarmingly low 1:0.60 over the next decade!

Hence, the total number of goods vehicle drivers would be around 7.0 million, with nearly 2.3 million trucks idling due to shortage of drivers. Last year MoRTH has removed the minimum education requirement (of Class 8) for obtaining a commercial vehicle driving license to improve employment opportunities, particularly for the underprivileged skilled persons.

Reasons for driver shortage
Despite their hard work, the truck drivers in India have never got the respect they deserve. In fact, one of the least respected professions in our society is that of the truck driver. They have not been accorded any position of dignity, largely owing to their absence in the routine social life of their families and communities. Often, they become a truck driver because they can find no other job and are looked upon with open disdain. In addition, the lifestyle practices and habits (and often even the character) of a truck driver are perceived negatively by society.

And remuneration to the truck drivers is one of most neglected areas of logistics operations in India. The average earning of a truck driver is around Rs 15,000 to 20,000 per month (including daily allowance or bhatta). 85 percent of the road transport industry is from the unorganised sector, or small fleet operators, and the drivers do not have any fixed working hours, benefit of minimum wages, and a defined rest period. The truck drivers are deprived of benefits like ESI, PF, bonus and leave. The majority of the drivers are uneducated and often learn driving on the job while working as a helper or cleaner and do not have any formal defensive driving training. Added to this is the larger problem of the typical driver having a "macho" attitude and a firm belief that all accidents are not preventable – "what has to happen, will happen". Hence, he may scorn away advice relating to speed limit or wearing of seat belt.

Very few young persons want to join this profession now. Unlike other developed countries, it is rare for an Indian truck driver’s son aspiring to be a truck driver. Often this is due to the driver’s children being better educated and hence exposed to more job opportunities which are better paying without the hardships faced by their father. Many young persons prefer employment in the industrial or service sectors or, in the rural areas, may even opt to earn a living under the Government’s MNREGA scheme whilst searching for a regular job.

Hardships faced by Indian truck drivers
An Indian truck driver is on the road almost every day of the month. His is a 24×7 job which involves driving long distances across various states. The truck is virtually his "home away from home" on the road. Surveys have revealed that almost 53 percent truck drivers suffer from a health issue, 23 percent battle sleep deprivation, about 18 percent face physical stress and 12 percent mental stress.

According to MoRTH, around 1.50 lakh people are killed in road crashes annually. As per a study conducted by the Central Road Research Institute (CRRI) exhausted and sleep deprived drivers account for nearly 40 percent of road crashes.

Of the 4.65 lakh road crashes every year, a quarter are linked to truck drivers with a fatality rate of around 25 percent. Also, 50 percent of the mishaps happen between sunset and sunrise as drivers prefer to drive in the night to escape police and RTO harassment during the day. This position has changed during COVID-19 as short and medium haul drivers (covering upto 400 km in a day) are not keen to eat out or spend time in roadside dhabas and want to be with their family by night time and have dinner at home.

As per road safety experts’ recommendations, drivers should not driver for more than 8 to 10 hours in a day and take regular breaks at least every 2 hours so that they stay alert. However, goods vehicle drivers in India often drive more than 10 to 12 hours a day. Whilst an average Indian driver may "rest" for 8 to 10 hours, he effectively sleeps for only 3 to 4 hours. (these figures have also changed during the pandemic, with drivers being on the road for shorter periods).

And many of them have to make do with sleeping in their uncomfortable truck cabin or even under their truck, often in the grueling heat during summers, for fear of getting robbed of diesel, cash or the goods in their vehicles. It is also not uncommon to find a driver cooking his meal under his truck or inside the cabin using a kerosene stove, with a complete disregard to his and others’ safety. Consequently, truck drivers are under physical and mental stress that results in accidents as they often doze off whilst driving.

CSR initiatives for truck drivers
A major component of the RSIP covered softer aspects relating to the driver community like their physical, mental and behavioural health, work-life balance and time for family, personal hygiene, cleanliness and habits, lifestyle and eating habits, literacy and education, and issues relating to self-esteem, dignity and respect. These were taken up across all plants under the CSR umbrella with positive and beneficial outcomes. Some of the major initiatives taken are enumerated below:

Health camps: Truck drivers are a highly vulnerable working population due to several health risk factors including poor eyesight and hearing loss, hypertension, fatigue, obstructive sleep apnea and sleep deprivation, and insufficient physical activity. Other risk factors are exposure to diesel exhaust and risk of developing lung cancer, poor diet, obesity, and other metabolic disorders. Furthermore, they are prone to risky behaviors and lifestyles such as smoking, tobacco/gutka chewing, drinking, substance abuse, and having casual sexual contacts. These can have an adverse impact on their health with a consequent risk of traffic accidents and health problems.

What started as occasional eyesight checking camps at ACC plant locations soon turned into a comprehensive health and medical check-up program as a regular on-going activity. These are usually organised by the medical staff of the plant hospital and often doctors from nearby towns are also called in. The primary aim of the health camps is to cover the following:

Vision: At least 65 percent of our truck drivers have some vision problem, mild or acute. The younger drivers may have myopia and may require their first pair of spectacles. The older drivers also need to be checked for signs of color blindness, cataract or glaucoma and may either need to replace their old specs or get reading glasses. Thousands of drivers have been covered in the eyesight camps and hundreds of drivers provided with free prescription spectacles, mostly on the spot. It is advisable for drivers to have their vision tested at least once every 2 years.
Hearing: Hearing loss can have the most significant impact on a truck driver’s ability to do his job. The occupational conditions of truck drivers may have bilateral, symmetrical harmful effect on hearing threshold sense in all frequencies, but mainly at a frequency of 4000 Hz. Periodic medical examinations are vital for pre-diagnosing and prevention of any possible impairment.

Blood pressure: Considered a silent ailment, as there may be no symptoms of the condition, uncontrolled BP can lead to serious health problems such as heart attack and stroke. Drivers found to be having higher than normal BP are generally advised to exercise, reduce salt in their food, drink lots of water, stop smoking and drinking alcohol, and get plenty of sleep. In fact sleep deprivation is a major reason for drivers having high BP.

HIV/AIDS: Truck drivers are at increased risk of HIV/AIDS infection and of contracting other STD diseases. As Ashok Alexander, who headed Avahan (an initiative by the Bill and Melinda Gates Foundation for HIV prevention in India) states in his book A Stranger Truth, HIV prevalence among truckers ranged from 3 to 7 per cent. Avahan’s research showed that long-distance truckers were the ones most at risk; the short-haul truckers got home every night. Health camps for drivers create awareness about HIV/AIDS and counselling for prevention.

Alcohol addiction and substance abuse (tobacco, drugs, etc): Drunk driving is responsible for approximately 20 to 30 percent of crash fatalities and injuries. Alcohol can seriously impair brake reaction time, steering responsiveness, and lane control. It also increases the tendency of over-speeding and other high risk driving behaviors. Health camps have special counselling sessions to make the drivers aware of the dangers of drinking and driving as well as the legal consequences and the disastrous impact on the driver’s family. Some of our plants came up with an interesting idea of putting the driver’s family photo in the driver cabin to serve as a reminder not to risk his life for the sake of his family who wait for him to come back home safely.

Personal accident and health Insurance: As part of the HSE program and keeping in view the high risk job nature of driving on company’s business, ACC introduced a Group Personal Accident Insurance policy for third-party truck drivers to ensure their safety and wellbeing. The policy covers accidental death and total or partial disability and serves to provide a secured life and future to the driver and his dependents.

It is heartening to note that the All India Transporters Welfare Association (AITWA) launched a mega project named "Highway Heroes" for the welfare of the truck driver community on 14th November 2019. The multi-dimensional welfare scheme includes provisions like free accident insurance, hospitalisation expenses, education help to children of drivers, training, and safety and a centralised national 24×7 helpline for access in case of an emergency like an accident, attack by criminals, theft or any other harassment.

The National Health Authority (NHA) also signed an MoU with AITWA on 14th November 2019 to provide healthcare services to truck drivers under the "Ayushman Bharat – Pradhan Mantri Jan Arogya Yojana" (PM-JAY) scheme. Under this partnership, the NHA and AITWA will work together to identify truck drivers and employees of transport companies who could be eligible beneficiaries of the scheme.

Respect and dignity: In India the truck drivers appear at the bottom of the pyramid when it comes to respect and historically have been privy to lack of praise and dignity. They rarely receive respect from civic authorities like RTO, police personnel and check-post officials and one frequently hears reports of discriminatory behavior and harassment to truckers. Most drivers do not have the educational background or knowledge to deal with legal complications.

It is unfortunate that the driver’s job in India has a social disrespect and stigma attached to it. A large number of drivers find it difficult to get married as people are reluctant to marry their daughter to a driver. The driver’s children do not want to become drivers and drivers themselves have a low self-esteem.

Regular interactive sessions with drivers at ACC’s plants (often in the form of Driver Chaupals) have helped to instill and reinforce self-confidence and dignity in the drivers. They are briefed on the role as being beyond that of a mere driver to that of a brand ambassador and the customer’s first point-of contact with the company. Some of our plants have taken innovative steps like providing laundry service, toilets with bathing facility and even hair-cutting saloons in their parking yards so that drivers can freshen themselves before commencing their trip and look presentable and clean when they reach their customer. Cleanliness, hygiene and grooming also helps to increase the driver’s self-confidence and self-respect. ACC’s Thondebhavi plant in Karnataka was the first to install a full length mirror in the driver rest facility so that he can see how others view him!

ACC’s Chanda plant (near Nagpur) was the first plant in the Indian cement industry to construct a state-of-the-art fully concrete parking yard of 4.5 acres for trucks, with safety features like fishbone parking, one-way movement, no reversing, adequate illumination and separate entrance and exit gates. The parking facility (designed by the renowned Arun Das Associates) has a specially designed resting facility for the drivers with beds, toilets with showers, restaurant, clean drinking water, TV, and recreational and games facilities. The facility had a marked impact on the drivers. Truckers now wanted to visited the plant to pick up loads as they looked forward to a comfortable stay and rest whilst they waited for their turn to be called to roll the truck inside the plant for loading. Proper food, shower and rest ensured an absence of fatigue and safe driving!

Work-life balance: One of the underlying themes of our CSR initiatives is aimed at providing the driver community with adequate work-life balance. This has been achieved through a multipronged strategy of

providing a financial security net through personal health and accident insurance policy
more efficient route planning and scheduling of trucks using Fleet Management
System supported by GPS truck tracking from "Gate Out to Gate In" (GOGI) and RFID for streamlining the "Gate In to Gate Out"(GIGO) flow of trucks inside the plant which help in optimising the truck transit time, thereby enabling drivers to spend less time on the road. The drivers can enjoy more time with their family, eat meals with them more frequently, and sleep better.

Rewarding safe drivers: ACC installed GPS based real time truck tracking systems (IVMS) in all third party dedicated vehicles (in a phased manner) to monitor and analyse driver performance using metrics like over-speeding, route deviation, sudden acceleration, harsh braking, harsh manoeuvring and power disconnection of IVMS.

The MIS is used to develop a monthly "Performance Report Card" of each driver as well as each Road Transport Contractor and the drivers with high performance scores are felicitated and rewarded for at functions attended by their family members (wives, children and sometimes even parents). Many drivers share personal experiences about driving safety and take a pledge to extend this message across the community. In many instances, the company has also sponsored their children’s education as a safe driving reward.

These award functions serve the twin purpose of motivating other drivers to drive safely and instilling a sense of pride and self confidence in them as well as their family members. The drivers also feel that they have earned the respect of the Management when they are called upon the stage to receive their awards. Some plants have even displayed life size photographs of drivers with good safety record in their plants to motivate them.

Driver Chaupal and toolbox talks: Plants have been organising "toolbox" safety talks for drivers as informal group discussions that focus on a particular safety issue (like driving in monsoon, or risk associated with worn out tyres, importance of rest and breaks, benefits of using seat belts, safe way of tarpaulin tying, use of PPE, danger of using mobile phones whilst driving, etc). These talks are used daily to promote a safety culture as well as to facilitate health and safety discussions, often with the help of a nukkad natak.

A unique initiative taken by some ACC plants was organising a "Driver Chaupal" on a weekly basis, attended by all drivers present in the parking yard on the particular day. These are typically like corporate "town halls" where drivers get an opportunity to voice their opinions on matters affecting them like plant amenities (drinking water, canteen facility etc) and the senior management can take quick action to redress any genuine grievances.

Seat belt usage: Very few truck drivers in India have a habit of wearing a seat belt, except at police check posts to escape being fined. A bigger concern is the absence of a proper driver seat and 3 Point retractable seat belts in the older truck models. Ideally, a driver’s seat needs to be with a head restraint, adjustable and fold-down backrest, vertical and fore-aft adjustment, adjustable lumbar support and adjustable seat angle. Many of the older trucks’ driver seats do not have these features and there is no provision for fitting a retractable seat belt. Often the trucks were found to have just a common belt strap with a buckle which the drivers will tighten across their stomach to escape from penalties or fines. Many drivers carried a belief that wearing a seat belt may put them at a greater risk as they may not be able to jump out in case the truck rolls over a hill. It took painstaking effort and scores of meetings with drivers and road transport contractors to dispel this wrong notion. We also impressed upon our road transport contractors to retrofit proper seat and seat belt.

ACC also launched a "Suraksha Kavach" ("security armour") drive at plants to successfully introduce the use of a Seat Belt Convincer to demonstrate the importance of wearing a seat belt whilst driving. The Seat Belt Convincer is a crash simulator training device that simulates a low impact vehicle collision (within a speed range of 8 to 15 kmph) to reinforce the benefits of wearing a seat belt whenever the vehicle is in motion.

Truck Simulators with adjustable virtual traffic, weather conditions and road layouts were also used to train drivers and manoeuvre the vehicles in different weather conditions and terrains. The simulator allows possibility of encountering dangerous driving conditions without subjecting the driver to physical risk.

Self-cooking facility: A majority of truck drivers do their own cooking using a kerosene stove and essential utensils. It is not uncommon to find the driver and helper lighting up a stove under their truck or inside the cabin, ignoring the immense fire and explosion hazard. Both as a CSR and safety initiative ACC created kitchen facilities near the drivers’ rest rooms, equipped with running water for cleaning utensils, drinking water and cooking gas stove. The drivers were delighted with this (free of charge) facility which reduced their hardship and provided a clean, hygienic, convenient and safe place to cook their meals. It also encouraged camaraderie amongst the drivers.

Conclusion
Though our CSR and Logistics Safety Excellence journey is a decade old, we realise we have a lot of ground to cover and, to quote Robert Frost, "have promises to keep and miles to go’. We also realise that it is not enough to pursue driver community issues as a side activity. Rather, uplifting the drivers" lives needs to be an integral part of our core business strategy. Through our initiatives we help our driver partners to earn a sustainable livelihood and live a life of self-respect, dignity and pride.

Foonote:
ABOUT THE AUTHOR:
Rajesh Seth, Director Logistics (Retd), ACC. He is IIM Ahmadabad, alumnus and has held many executive positions during his association with ACC Ltd. Today he is a visiting faculty and advisor on logistics.

BOX:
ACC’s road safety improvement programme
To tackle some of the above issues, ACC embarked on a Logistics Safety Excellence journey in 2011 with a holistic Road Safety Improvement Programme (RSIP) with a "Zero Harm" vision spanning across all the seventeen cement plants and its subsidiary Bulk Cement Corporation (India) at Kalamboli (in Navi Mumbai). RSIP had a clear, well-defined objective focusing on People, Vehicles and Processes. The program was designed in a modular format in two phases -Phase 1 covering 8 easy-to-implement steps ("low hanging fruits") and Phase 2 covering 16 steps (requiring a longer period for implementation). There was a strong emphasis on knowledge sharing and replication of best practices across all plants.

The RSIP essentially focused on:
People/Partners – defensive driving training and CSR initiatives for drivers
Vehicles – their maintenance, adherence to a 30-point checklist and road worthiness, and
Processes – traffic management, hazard identification-cum-mitigation, Journey Risk Mapping (JRM) and Driver Management Centers (DMCs).

The DMCs were set up at all plant locations to provide valuable support like
Defensive Driving Induction training (DDI) for new drivers,
Defensive Driving Courses for all drivers,
Training through truck simulators,
In-cab assessment, and
JRM briefings and debriefings
Driver performance assessment using "In Vehicle Monitoring System" (IVMS) and GPS

A Transport Control Tower (TCT) was set up in 2018 as a nodal point to monitor the driving patterns of the drivers and provide them counselling on safe driving. The installation of IVMS brought more vehicles within the ambit of TCT monitoring and counselling. In-camera counselling for drivers was also launched across all plants. Anti-toppling devices were fitted in transit mixers to prevent accidents caused by roll-over of mixers.

Another unique initiative was the introduction of "driver passport" for each driver (certifying his fitness to drive on company’s work) and a "Vehicle Passport" for each vehicle (certifying its road worthiness to ply on company’s business. These were earlier manual, but later changed to an electronic format. Around 30,000 vehicles and drivers (outbound and inbound) belonging to over 250 Authorised Road Transport Contractors were covered under the program. This practice was also shared with the Cement Sustainability Initiative (Task Force 3 for Driving and Contractor Safety) of the global CEO-led World Business Council for Sustainable Development (WBCSD) and adopted by other CSI member companies in the Indian cement industry.

Concrete

Grinding aids help in reducing the agglomeration of particles

Published

3 weeks ago

August 23, 2024

Roshna

Lokesh Chandra Lohar, General Manager – Technical and Executive Cell, Wonder Cement, shares insights on overcoming challenges, leveraging innovations and the crucial role of R&D in maintaining high standards in cement production.

Can you provide an overview of the grinding process in your cement manufacturing plant and its significance in the overall production process?
Cement grinding unit is used to grind clinker and gypsum into a fine powder, known as cement. The process of grinding involves grinding of the clinker to a fine powder, which is then mixed with gypsum, fly ash and other additives to produce cement.
At Wonder Cement, our grinding processes are pivotal in ensuring high-quality cement production by utilising state of art technologies ex. Vertical Roller Mill (VRM), roller press with ball mill in combi circuit and finish mode grinding and high-efficiency classifier, have achieved optimal particle size distribution and energy efficiency.
Our commitment to sustainability is evident with usage of energy-efficient equipment, eco-friendly grinding aids and renewable energy sources. Continuous research and development efforts ensure we stay at the forefront of innovations, optimising our grinding operations and minimising impact on the environment.

The main processes involved in a cement grinding unit are:

Clinker grinding: This is the main process in a cement grinding unit, where the clinker is ground into a fine powder using a ball mill or combi mills (RP+ Ball Mill) or vertical roller mill circuit. The grinding process is controlled to achieve the desired fineness of the cement.
Gypsum and other additives: Gypsum is added to the clinker during the grinding process to regulate the setting time of the cement. Other additives such as fly ash, BF slag and pozzolana may also be added to improve the performance of the cement.
Packaging: Once the grinding process is complete, the cement is stored in silos before being packed in bags or loaded into bulk trucks for transportation.
Quality control: Quality control measures are in place throughout the grinding process to ensure that the final product meets the required specifications, including strength, setting time, and consistency.What are the main challenges you face in the grinding process, and how do you address these challenges to maintain efficiency and product quality?
The main challenges in the grinding process include high energy consumption, frequent wear and maintenance, variability in clinker properties, environment impact and ensuring consistent product quality. To address these challenges, we have implemented several strategies:
High energy consumption: Clinker grinding is energy-intensive, and high energy costs can significantly impact the overall production costs of cement.
This is one of the primary challenges in the grinding process.
Use of high-efficiency equipment: We have state-of-the-art energy-efficient grinding equipment, such as vertical roller mills (VRM), Combi Circuit (roller press with ball mill), which consume significantly less energy consumption.
Process optimisation: Real time monitoring and optimisation of the grinding process to minimise energy consumption.
Frequent wear and maintenance: The grinding equipment, such as mills and crushers, is subjected to wear over time. Frequent maintenance and downtime can affect production efficiency.
Regular maintenance: Implement a proactive maintenance schedule to address wear and tear promptly, ensuring the equipment remains in optimal condition.
Proper lubrication: Adequate lubrication of moving parts can extend the lifespan of grinding equipment.
Use of wear-resistant materials for components, which are prone to wear and abrasion.
Variability in clinker properties: Clinker properties can vary from one batch to another, leading to inconsistencies in the grinding process and the quality of the final cement product.
Clinker sources: At Wonder we have one clinker source, which is our mother plant at Nimbahera, Rajasthan and we distribute clinker to various split GU’s from Nimbahera. This helps us to maintain uniform clinker quality across each location.
Quality control: Rigorous quality control measures help us identify and address variations in clinker properties. Adjust grinding parameters as needed to compensate for these variations. (ex. use of cross belt analyser and on-line particle size distribution)
Environmental impact: Energy-intensive grinding processes can have environmental repercussions due to high dust emissions and energy consumption.
Use of high efficiency dust collection and suppression system to keep emissions below statutory norms
Sustainable grinding aids: Consider using eco-friendly grinding aids that enhance grinding efficiency without compromising cement quality and environmental standards.
Alternative fuels: Use alternative and more sustainable fuels in the cement kiln and hot gas generated to reduce carbon emissions.
Use of clean energy in logistics:
To reduce carbon emissions, sustainable alternatives are also sought for inland transport. We have involved neutral internal transports (electric powered trucks).
Automation and digitalisation of production:
Wonder Cement has already initiated the process to implement Smart Cement Industry 4.0.
With Industry 4.0, the automation and digitalisation of operations, including the use of sensors, remote diagnosis, analysis of big data (including the artificial intelligence analysis of unstructured data such as images and video), equipment, virtual facilities, and intelligent control systems will be done automatically (based first on ‘knowledge capture’ and then on machine learning). For Process optimisation we are using the FLS Process expert system (PXP) system. This allows for system optimisation and increased efficiency gains in production.

How do grinding aids contribute to the efficiency of the grinding process in your plant? What types of grinding aids do you use?
Grinding aids help in reducing the agglomeration of particles, thus improving the overall grinding efficiency and ensuring a smoother and more efficient grinding process without having adverse effect on any of the properties of the resulting cement. In cement manufacturing, various types of grinding aids are used to improve the efficiency of the grinding process. These include:

Glycol-based grinding aids

Composition: Ethylene glycol and diethylene glycol.
Usage: Commonly used in to improve the grinding efficiency and reduce energy consumption.

Amine-based grinding aids

Composition: Triethanolamine (TEA) and Triisopropanolamine (TIPA).
Usage: Effective in improving the grindability of clinker and other raw materials, enhancing cement strength and performance.

Polyol-based grinding aids
Composition: Polyethylene glycol and other polyol compounds.
Usage: Used to improve the flowability of the material and reduce the tendency of particles
to agglomerate.

Acid-based grinding aids
Composition: Various organic acids.
Usage: Used to modify the surface properties of the particles, improving the grinding efficiency and final product quality.

Specialty grinding aids

Composition: Proprietary blends of various chemicals tailored for specific materials and grinding conditions.
Usage: Customised to address challenges in the grinding process, such as the use of alternative raw materials or specific performance requirements.

Can you discuss any recent innovations or improvements in grinding technology that have been implemented in your plant?
Recent innovations and improvements in grinding technology:

Selection of state-of-the-art vertical roller mills along with high efficiency classifier (VRMs): VRMs are more energy-efficient and have lower power consumption, leading to significant energy savings. They also provide a more consistent product quality and require less maintenance. For raw meal grinding, we have both VRM and roller press.
Wear-resistant materials and components: Upgrading grinding media, liners and other components with wear-resistant materials. These materials extend the lifespan of the equipment, reduce downtime, and lower maintenance costs. Examples include ceramic liners and high chrome grinding media.
Intelligent monitoring and predictive maintenance: Utilising IoT sensors and predictive analytics to monitor equipment health. Predictive maintenance helps identify potential issues before they lead to equipment failure, reducing unplanned downtime and maintenance costs. It ensures optimal performance and prolongs equipment life.
Optimisation software and simulation tools: Using simulation software to model and optimise the grinding process. These tools help in understanding the process dynamics, identifying bottlenecks, and testing different scenarios for process improvement. This leads to better process control and efficiency.

How do you ensure that your grinding equipment is energy-efficient and environmentally sustainable?

Energy-efficient grinding technologies such as VRMs: VRMs are more energy-efficient than traditional ball mills due to their ability to grind materials using less energy.
Benefits: Up to 30 per cent to 40 per cent reduction in energy consumption.
Use of renewable energy sources (solar power integration): Utilising solar power for grinding operations
Implementation: Signing of long-term open access power purchase agreements (PPA) with renewable energy developers
Benefits: Reduces reliance on fossil fuels, decreases greenhouse gas emissions.

Environmental sustainability practices

a. Dust collection and emission control
Description: Using bag filters, and covered material handling system
Implementation: Installing and maintaining high-efficiency dust control equipment.
Benefits: Reduces particulate emissions, improves air quality, complies with environmental regulations.
b. Water conservation
Description: Recycle and reuse water in the grinding process.
Implementation: Installing sewage treatment plant (STP)
Benefits: Reduces water consumption, minimises environmental impact.
c. Use of alternative raw materials
Description: Incorporating industrial by-products like fly ash, BF slag and chemical gypsum in the grinding process.
Implementation: Sourcing and blending alternative materials.
Benefits: Reduces the need for natural resources, lowers carbon footprint, enhances sustainability.
By implementing these practices, the plant ensures that its grinding operations are both energy-efficient and environmentally sustainable, aligning with industry best practices and regulatory requirements.

What role does research and development play in optimising your grinding processes and the selection of grinding aids?
Following is the role of research and development in optimising grinding processes and selecting
grinding aids:

Testing and usage of new low-cost cementitious material: Dedicated R&D teams work on developing and new low-cost cementitious material to reduce clinker factor in cement and
improve efficiency.
Process simulation and modelling: Uses simulation and modelling tools to understand the dynamics of the grinding process and identify areas for improvement.
Formulation of new grinding aids with reverse engineering: Formulate new grinding aids to enhance the efficiency of the grinding process.
Testing and evaluation: Conducting laboratory and plant-scale tests to evaluate the effectiveness of different grinding aids.
Collaboration with industry partners: Collaborating with suppliers, universities and research institutions to stay at the forefront of grinding technology advancements.

Research and development play a crucial role in optimising grinding processes and selecting the appropriate grinding aids. By focusing on innovation, process optimisation, sustainability and continuous improvement, R&D ensures that the plant remains competitive, efficient, and environmentally responsible. This commitment to research and development enables the plant to achieve higher productivity, lower costs and produce superior quality cement.

What trends or advancements in grinding processes and grinding aids do you foresee impacting the cement manufacturing industry in the near future?
The trends and advancements in grinding processes and grinding aids that we see coming up in the near future are:

1. Digitalisation and Industry 4.0

Advanced process control (APC) and automation
Internet of things (IoT) and predictive maintenance
Artificial intelligence (AI) and machine learning (ML)

2. Energy efficiency and sustainability

Energy-efficient grinding technologies
Use of renewable energy

3. Innovations in grinding aids

Eco-friendly grinding aids
Tailored grinding aids
Multifunctional grinding aids

4. Advanced materials and components

Wear-resistant materials for liners
High-density grinding media

5. Process optimisation and integration

Holistic process optimisation

6. Sustainability and circular economy

Circular economy practices
Carbon capture and utilisation (CCU)

– Kanika Mathur

Concrete

Shaping the Future

Published

2 months ago

July 16, 2024

admin

Jigyasa Kishore, Vice President Enterprise Sales and Solutions, Moglix discusses the critical role of cement capacity expansion in India’s infrastructure development, highlighting the importance of technological advancements, sustainability and strategic investments amid market challenges.

With an installed cement capacity of 600 million tonnes, India is the second-largest cement producer in the world. Cement consumption in India is expected to reach 450.78 million tonnes by the end of FY27, owing to rapid urbanisation and smart city development plans. Infrastructure, typically, receives the most funding from the government which bodes well for the cement industry. At a time when India is urbanising and building infrastructure at breakneck speed, the role of cement capacity expansion is becoming critical. This expansion, today, supports the market demands as well as contribute towards the nation’s economic ambitions.

Setting a firm foundation
Cement is an essential component in the construction of any nation. Roads and bridges, airports and public buildings all indicate cement’s critical importance in infrastructure development. Urbanisation is fuelled by it through the creation of housing projects aimed at achieving economic growth and development. Here’s why capacity expansion of cement production is critical:
Urbanisation: The demand for cement increases as urbanisation intensifies. This is further evidenced by the budget estimate for the Pradhan Mantri Awas Yojana for affordable housing, which has been pegged at US$ 9.63 billion (Rs.79,590 crore) for the first time, registering an increase of 66 per cent over the previous year’s budget.
Major infrastructure projects: Large infrastructure projects like highways, bridges, and city-development require considerable quantities of cement. Capacity expansion can ensure steady supplies of good-quality cement to these large-scale projects and see their timely and expeditious completion. The National Infrastructure Pipeline (NIP) has been widened to 9,735 projects worth $1,828.48 billion. Many of the upcoming projects will be heavily dependent on the cement industry. In addition, the PM Gati Shakti National Master Plan for infrastructure is further driving up the
cement demand.
Employment Generation: Increased production capacity directly results in job creation in the cement industry. Additionally, a corresponding demand for further employment in complementary sectors such as construction, logistics, and retail is also generated. This bolsters holistic economic development and prosperity.
Regional Economic Growth: New cement plants are often set up in regions with abundant raw materials but stunted industrial development. By setting up new plants in these regions, local resources can be leveraged and the overall growth story of the region can be improved. For instance, Dalmia Bharat recently announced a $10.9 million investment for further expansion of its already existing cement plant in the small town of Banjari in Bihar. The increasing presence of small and mid-size cement players across various regions helps dilute market concentration of industry leaders, leading to a more competitive and diverse market landscape.

Reinforcing the Structure
India’s cement industry is currently experiencing a tough fiscal year and there has been a downturn in pricing. Moderate demand is expected for H1FY25. Temporary setbacks such as labour shortage and heavy monsoons have also caused the demand for cement to take a dip in the past couple of months.
Needless to say, expanding capacity during periods of subdued demand involves risk. Cost implications of such investments can be significant. And firms could fail to recoup their investments if market conditions don’t improve as planned. Over-expansion could also result in an oversupplied market and further impact the prices as well as profit margins. Cement producers are currently under pressure due to reduced prices and slow demand. While this price dip might adversely affect profits in the short term, it could be seen as market adjustment ahead of a surge in anticipated demand during the second half of the fiscal year
Periods of uncertainty can be looked at as opportunities for companies to diversify risks and invest in innovation. Developing and launching new cement products for specific use-cases would contribute to the top line. Targeting export markets for better demand can also ensure the optimal use of additional capacities. At the same time, focusing on operational efficiencies would help the companies keep the cost of production in check.
New investments made in cement production facilities automatically come with the latest technological advancements that can enhance efficiency, minimise environmental impacts, and improve the quality of cement. This leads to construction practices that are more durable and sustainable. JSW, for instance, has initiated research on the integration of supplementary cementitious materials (SCMs) like fly ash, slag, calcined clay, and more. These materials not only improve the durability and strength of cement but also contribute towards reduction of carbon footprint of the cement industry. In order to meet energy demands sustainably, we must look at better industry practices such as usage of waste heat recovery systems, high-efficiency coolers and preheaters, and transition towards clean energy sources like solar or wind power.
There is also a growing need for cement companies to become environmentally conscious. Modern cement plants are increasingly adopting greener technologies owing to the decarbonisation pressure. Capacity expansion while keeping sustainability at its core will help check environmental impact of cement production while also aligning with the challenging global environment-conservation goals. Recently, UltraTech announced that it had received Environmental Product Declaration (EPD) certificates for four of its cement products. Similarly, Dalmia Bharat (Cement) has announced plans to produce 100 per cent low-carbon cement by 2031 and has a US$ 405 million carbon capture and utilisation (CCU) investment plan to achieve this goal. Such efforts are laudable and set a fine example for all industry players.

Shaping a Stronger Nation
Cement capacity expansion is a strategic move for the Indian cement industry. While short-term market fluctuations present challenges, continued investment in capacity expansion reflects a long-term vision for shaping India’s future infrastructure landscape. The current economic climate demands agility and innovation from Indian cement players. The leaders need to lead by example. By adopting industry best-practices, aiming for sustainable development, and working towards continuous growth and advancement, the cement industry is sure to rise like a phoenix from the ashes.

About the author
Jigyasa Kishore comes with 15+ years of experience at building brands, enabling enterprise growth, and transforming organisational performance with a technology-first approach. At Moglix, she leads brand growth as a digital supply chain solutions architect for large manufacturing enterprises.

She is an alumnus of the Indian

School of Business, Hyderabad, and Bangalore University.

Concrete

Filtration can help to control climate change

Published

5 months ago

April 16, 2024

admin

Niranjan Kirloskar, Managing Director, Fleetguard Filters, elaborates on the importance of filtration and its profound impact on efficiency, longevity and environmental sustainability.

Tell us about the core principle of filtration.
Filtration is segregation/separation of matter by density, colour, particle size, material property etc. Filtration is of four basic types:

Separation of solids from gas
Separation of solids from liquids
Separation of liquids from liquids
Separation of Solids from solids.

As applied to engines/equipment, the main objective of filtration is to purify the impurities and provide the desired fluid or air for enhanced engine/equipment performance in turn optimising their performance and life.

Can better filtration bring productivity to the work process? How?
Better filtration can improve the quality of application performance in multiple ways. Filtration improves engine performance as it filters and prevents dirt, dust, and debris from entering into the engine. This ensures that the quality of air or fluid that reaches the combustion chamber is as per the specific requirements of optimal performance of the engine. It also extends engine life by filtering out contaminants. Efficient filtration ensures optimal performance of the engine/equipment over its entire operating life. Filtration also improves fuel efficiency as a clean filter allows for a better air-fuel mixture in the engine, thus improving combustion efficiency, which in turn results in better fuel economy. It keeps emissions under control as fuels burn more efficiently leading to lesser harmful residue in the environment. Thus, to sum up, an optimal filtration solution ensures better performance, prolonged engine life and less hazardous waste in the environment.

What is the role of technology in the process of filtration?
Innovation, research and development as well as technology play a pivotal role in catering to the ever-evolving environmental norms and growing market demands. At FFPL we have NABL Accredited labs for testing, we have ALD Labs for design, and a team of R&D experts constantly working on providing advanced solutions to cater to the evolving market needs. We have robust systems and advanced technologies that make high-quality, high-precision products. Our state-of-the-art manufacturing facilities use advanced technologies, automation, robotics and also Industry 4.0 as applicable to provide the best products to our customers. To ensure each product delivered to market is of utmost precision, advanced quality equipment such as CMM, scanning systems and automated inspection technologies for real-time monitoring and quality control during the manufacturing of filtration systems and to comply with standard quality requirements are used.

Tell us about the impact of good filtration on health and the environment.
Good filtration of equipment is to the environment what a good respiratory system is to the body. There are various benefits of an efficient air filtration system as it improves the air quality by ensuring optimum combustion of fuel thereby reducing/controlling emissions to the environment. Efficient lube filtration ensures low wear and tear of the engine thereby extending life of the engines and maintaining optimal performance over the entire operating life of the engine. Efficient fuel filtration ensures low wear and tear of expensive and sensitive fuel injection thereby ensuring perfect fuel metering resulting in best fuel efficiency and saving of precious natural resources. This efficient filtration can help to control climate change as it reduces the carbon footprint due to combustion in the environment.

Can your products be customised and integrated with other machinery?
Fleetguard Filters have been known as a leading solutions provider for decades. With relevant experience and close customer relations, we understand the market/applications requirements and develop solutions to address the pressing technical challenges our customers face concerning filtration solutions. Filters can be customised in terms of size, shape and configuration to fit specific requirements. Customised filters can be designed to meet critical performance requirements. Filtration systems can be designed to integrate seamlessly with any auto and non-auto application requirements.

What are the major challenges in filtration solutions?
Major challenges faced in filtration solutions are:

With every emission regulation change, filtration requirements also keep changing.
Engines are being upgraded for higher power ratings.
Space for mounting filtration solutions on vehicles/equipment is shrinking.
For fuel injection systems, the water separation efficiencies are becoming more and more stringent, so are particle separation efficiencies.
Due to next level filtration technologies,filtration systems and filter elements are becoming expensive, thereby increasing TCO for customers.
Customers prefer higher uptimes and longer service intervals to ensure lower maintenance and operating costs.

We, at Fleetguard, strive continuously to ensure that all the pains experienced by our customers are addressed with the fit to market solutions. Balancing the cost of filtration solutions with their performance and durability can be challenging, especially where the requirements of high filtration standards are required. Also, wrong disposal methods for used filters can have environmental impact.